Impact dissipating helmet liners with cylindrical retaining posts

ABSTRACT

Impact dissipating helmet liners and protective barriers having internal cylindrical posts or pins are provided. The helmet liners and protective barriers include a flexible, fluid impermeable enclosure having an upper wall, an opposing lower wall, and a sidewall extending between the upper wall and the lower wall; a fluid contained in the enclosure; and cylindrical posts or pins extending from the lower wall to the upper wall, each of the cylindrical posts or pins at least partially restraining deflection of one of the upper wall and the lower wall. The helmet liners provided may include a central portion and lobes radially extending from the central portion and are adapted to conform to the shape of a helmet shell. The protective barriers disclosed may be constructed in any convenient shape compatible with the intended application of the protective barrier. Methods of fabricating helmet liners and protective barriers are also provided.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority from pending U.S. Provisional Patent Application 63/199,919, filed on Feb. 3, 2021, the disclosure of which is included by reference herein in its entirety.

BACKGROUND OF THE INVENTION Technical Field

Aspects of the present invention relate generally to protective barriers and headgear, such as, helmets. More particularly, aspects of the invention, in its several embodiments, provide protective, fluid-containing, impact-dissipating liners, for example, helmet liners, having reinforcing pins or posts that enhance the performance and/or durability of the liners.

Description of Related Art

Numerous human activities, such as, recreation and sports, public protection, and armed service, expose the human body, especially, the head, to impact and injury.

Head injury can be the most traumatic type of bodily injury. Especially when in motion, the exposure of the human head to contact and injury can be a continuous concern, whether the motion is while in a motorized vehicle or on a bicycle. Many attempts have been made in the art of head protection to minimize damage to the skull, brain, and brain stem due to head impact.

Many prior art attempts to address this concern have yielded various helmet designs that provide impact energy absorbing materials, for example, foam rubbers and plastics, in an attempt to provide as much “cushioning” material between the surface of impact and the head. Accordingly, in the state of the helmet art in the early 21^(st) century, it is typical to provide as much foam cushioning within a helmet without detracting from the aesthetic appearance of the helmet. The resulting helmets have been limited in their success in meeting either goals of head protection or aesthetics.

Among other things, as the amount of cushioning material, for example, plastic foam, increases, the larger the envelope and the greater the exposure of the resulting helmet. Specifically, though a larger volume of cushioning material within a helmet may absorb more impact energy, and lessen the amount of impact energy transmitted to the head, the larger volume also increases the torsional movement arm between the point of contact and, for example, the neck, brain stem, and spinal cord of the helmet wearer. Accordingly, providing impact protection while minimizing torsional loading on the wearer is desirable.

Though of relatively minor consequence to some users, the larger the amount of cushioning material typically also results in a more unsightly appearance of the resulting helmet to the typical helmet wearer. Accordingly, there is a need in the art to ensure proper head protection, while, it is preferred, providing an aesthetically appealing helmet.

Though many forms of activity can expose the head to impact loading, athletic completion or contact sports can be one of the more acute concerns for helmet design and head protection. It is well recognized that the repeated contact of the head in such contact sports as football, hockey, and soccer expose the athlete, even though protected with some form of head gear, to degenerative brain damage. The occurrence of chronic traumatic encephalopathy (CTE) in professional athletes, especially in former professional football and hockey players, is well documented. It is generally believed that the repeated exposure of the head to impact loading, even when protected, can result in deteriorating and life changing effects upon cognitive abilities and behavior. Efforts continue to be made to investigate the cause of CTE and to mitigate or prevent its occurrence. Accordingly, there is need in the art to provide more protective headgear for athletes and others.

In addition to head protection, many other bodily, structural, or ornamental surfaces can be exposed to damage due to damaging contact and/or impact loading. Enhancements in, for example, body armor or padding, for bodily protection during military activity, construction, or personal protection, among other activities, continue to be needed. The protection of general walls, barriers, and other surfaces from damage is also desirable.

U.S. Pat. No. 8,856,972 of Kirshon first introduced the concept of liquid-filled, fluid-displaced liner technology to the art. Subsequent advancements in the liquid-filled, fluid-displaced liner art are shown in U.S. Pat. No. 10,531,699 of Kirshon and related pending U.S. applications. This technology is marketed by KIRSH Helmets of Schenectady, N.Y. under the trademarks Fluid Displacement Liner™ technology or FDL™ technology. Though the inventions disclosed in the '972 and '699 patents provide an effective means for dissipating impact loading, further improvements and advantages are provided by the present inventions.

Aspects of the present invention provide protective impact-dissipating liners, for example, headgear, methods of minimizing the transfer of impact loads upon a surface, such as a human body, and methods of fabricating such impact-dissipating liners.

SUMMARY OF THE INVENTION

Aspects of the present invention provide improved impact-dissipating liners, helmets, and barriers that employ liquid-filled liner technology by providing pins or posts within the liner to, among others, assist in retaining the desired shape of the liner. In one aspect, the presence of the pins or posts within the liner disclosed herein may enhance the fluid displacement within the liner during impact and improve the performance of the liner.

In one embodiment an impact dissipating helmet liner is provided comprising or including: a flexible, fluid impermeable enclosure having an upper wall, an opposing lower wall, and a sidewall extending between the upper wall and the lower wall; a fluid contained in the enclosure; and a plurality of cylindrical posts or pins extending from the lower wall to the upper wall, each of the plurality of cylindrical posts restraining deflection, at least partially, of one of the upper wall and the lower wall. In one aspect, the liner may further include at least one cavity between the upper wall and the lower wall, the at least one cavity having a cavity sidewall extending from the upper wall to the lower wall.

In one aspect, each of the plurality of cylindrical posts may comprise solid cylindrical posts, for example, solid cylindrical posts that are devoid of any internal voids or cavities.

In another aspect, the impact dissipating helmet liner may further include at least one fabric sheet, for example, at least one woven fabric, unwoven fabric, or a knitted fabric sheet to, among other things, enhance the structural strength of the liner. The fabric sheet may be a polyethylene terephthalate (PET) sheet, a polyester sheet, or an aramid polymer sheet.

In one aspect, the flexible, fluid impermeable enclosure of the liner may include a central portion and a plurality of lobes extending from the central portion, for example, wherein the central portion and the plurality of lobes are adapted to conform to the shape of an internal surface of a helmet. In one aspect, the plurality of lobes may define radially extending cavities between adjacent lobes.

In another aspect, the flexible, fluid impermeable enclosure of the liner may be made of silicone rubber, for example, cured liquid silicone rubber.

In one aspect, the fluid within the enclosure may be a liquid, for example, a liquid silicone rubber, a polydimethylsiloxane, or a polyol.

As disclosed herein, the impact dissipating helmet liner disclosed herein may be used in a broad range of headgear and helmets, for example, for sports, for construction, for police, and for the military.

Another embodiment of the invention is a helmet having the impact dissipating helmet liner disclosed herein, for example, a helmet having a helmet shell containing the impact dissipating helmet liner disclosed herein.

Another embodiment of the invention is a protective barrier comprising or including a flexible, fluid impermeable enclosure having an upper wall, an opposing lower wall, and a sidewall extending between the upper wall and the lower wall; a fluid contained in the enclosure; and a plurality of cylindrical posts extending from the upper wall to the lower wall, each of the plurality of cylindrical posts restraining deflection, at least partially, of one of the upper wall and the lower wall. In one aspect, the protective barrier may be used or bodily protection, for example, used for body armor or body padding. In other aspect, the protective barrier may be used for structural protection, for example, for a wall or a surface, for example, a protective barrier for motor sports or sports arenas.

These and other aspects, features, and advantages of this invention will become apparent from the following detailed description of the various aspects of the invention taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter, which is regarded as the invention, is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other objects, features, and advantages of the invention will be readily understood from the following detailed description of aspects of the invention taken in conjunction with the accompanying drawings in which:

FIG. 1 is a perspective view of an impact dissipating helmet liner according to an aspect of the present invention.

FIG. 2 is a top plan view of the helmet liner shown in FIG. 1.

FIG. 3 is a cross sectional view of a portion of the helmet liner shown in FIG. 2 as viewed along section lines 3-3 shown in FIG. 2.

FIG. 4 is a cross sectional view of a portion of the helmet liner shown in FIG. 2 as viewed along section lines 4-4 shown in FIG. 2.

FIG. 5 is a top perspective view of a portion of a liner according another aspect of the invention.

FIG. 6 is a bottom perspective view of the portion of the aspect of the liner shown in FIG. 5.

FIG. 7 is a cross-sectional view of a helmet having either the impact-dissipating liner shown in FIGS. 1 through 4 or a liner formed from the liner portion shown in FIGS. 5 and 6, according to an aspect of the invention.

FIG. 8 is a cross-sectional view of a representative portion of a protective barrier having the structure of either the impact-dissipating liner shown in FIGS. 1 through 4 or of a liner formed from the liner portion shown in FIGS. 5 and 6, according to an aspect of the invention.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 is a perspective view of an impact dissipating helmet liner 10 according to one aspect of the present invention. FIG. 2 is a top plan view of the helmet liner 10 shown in FIG. 1. Hidden lines of liner 10 appear in phantom in FIGS. 1 and 2. Though aspects of the invention may be referred to as “liners” or “helmet liners” in the following to facilitate disclosure of aspects of the invention, it is to be understood that the features and aspects of the invention disclosed herein are not limited to helmet liners, but apply to other protective barriers. For example, these protective barriers include, but are not limited to, body armor, body padding, barrier protectors, surface padding, and surface protectors.

As shown in FIGS. 1 and 2, impact dissipating helmet liner 10 includes a flexible, fluid impermeable enclosure 12 having an upper sheet or wall 14, an opposing lower sheet or wall 16, and a sidewall 18 extending between the upper wall 14 and the lower wall 16; a fluid 20 contained in the enclosure 12; and a plurality of cylindrical posts or pins 22 extending from the lower wall 16 to the upper wall 14. In one aspect, upper wall 14, lower wall 16, and sidewall 18 of enclosure 12 define a cavity 21 containing the fluid 20, for example, a fluid, such as, water, an oil, a liquid silicone rubber, a polydimethylsiloxane, or a polyol, among other fluids.

The impact dissipating helmet liner 10 shown in FIGS. 1 and 2, illustrates one form of a liner that may be provided according to an aspect of the invention. However, it is envisioned that other aspects of the invention, for example, the protective barriers, may have different shapes. For example, protective barriers according aspect of the invention may comprise any shape conducive to the desired application, for example, a hexahedron (such as, a cube, a rectangular prism, or a cuboid), a prism (such as, a triangular, pentagonal, or hexagonal, or octagonal prism), or a cylinder, such as, a right cylinder (such as, a circular, elliptical, triangular, rectangular, pentagonal, hexagonal, or octagonal, cylinder). It is envisioned that other regular and irregular three-dimensional shapes may be used according to aspects of the invention, for example, when providing body armor, body padding, barrier protectors, surface padding, and surface protectors, among other applications of the invention.

In one aspect, each of the plurality of cylindrical posts or pins 22 may comprise a solid post or pin, for example, having little or no internal cavities, voids, holes, or hollows. In one aspect, the cylindrical posts or pins 22 may include one or more voids, for example, a hollow or a hole, for example, an axially directed cylindrical hollow or an axially directed cylindrical through hole. In one aspect, each of the plurality of cylindrical posts 22 may restrain deflection, at least partially, of the upper wall 14, the lower wall 16, and/or both the upper wall 14 and the lower wall 16 of liner 10. Though in one aspect posts 22 may be circular cylindrical in shape, for example, right circular cylindrical in shape as shown in FIGS. 1 and 2, it is envisioned and deemed an aspect of the invention, that posts 22 may not be circular cylindrical, but cylindrical in any appropriate shape, including ellipsoidal or oval cylindrical or polygonal cylindrical, for instance, triangular cylindrical, square cylindrical, rectangular cylindrical, pentagonal cylindrical, or hexagonal cylindrical, among other polygonal cylindrical shapes. Again, any one of these cylindrical shapes of posts 22 may be right cylindrical or non-right cylindrical.

As also shown in FIGS. 1 and 2, in one aspect, the liner 10 may further include at least one hole or cavity 24 between the upper wall 14 and the lower wall 16. The at least one hole or cavity 24 may be a through hole or a blind hole, for example, having one or both ends sealed or covered, for example, by a portion of upper wall 14 or of lower wall 16. In one aspect, the at least hole or cavity 24 may have a hole or cavity sidewall 26 extending from the upper sheet or wall 14 to the lower sheet or wall 16. According to one aspect, the sidewalls 26 defining the cavities 24 may distinguish from the solid, cavity-less posts or pins 22 disclosed herein. In one aspect, while posts or pins 22 may function to retrain, for example, to at least partially restrain, the deflection of upper wall 14 and/or of lower wall 1, sidewalls 26 may function to define and/or bound the extremities of cavities 24 and may also restrain the deflection of upper wall 14 and/or the lower wall 16. In one aspect, it is envisioned, that holes or cavities 24 and sidewalls 26 may be omitted.

According to one aspect of the invention, at least one of upper wall 14 and lower wall 16 may include one or more layers or sheets of fabric 28, 30, 32, and/or 34, for example, a reinforcing fabric, that, according to aspects of the invention, can provide enhanced strength and durability to liner 10 such that liner 10 can provide enhanced protection. In one aspect, fabric sheets 28, 30, 32, and 34 may be similar in construction, fabrication, and integration into liner 10 as shown and descried in pending U.S. application Ser. No. 16/595,135, filed on Oct. 7, 2019, the disclosure of which is included by reference herein in its entirety.

According to aspects of the invention, one or more layers or sheets of fabric 28, 30, 32, and/or 34 may comprise any woven, non-woven, knitted, or non-knitted fabric or sheet material. In one aspect of the invention, one or more layers or sheets of fabric 28, 30, 32, and/or 34 may be referred to as a “fabric,” however, it is envisioned that any form of thin material, cloth, or textile may be used for one or more layers or sheets of fabric 28, 30, 32, and/or 34 and provide enhancements to the liner 10 disclosed herein. In one aspect, one or more layers or sheets of fabric 28, 30, 32, and/or 34 may be any form of thin material made by, for example, weaving, felting, and/or knitting, for example, of natural and/or synthetic fibers and/or filaments. In one aspect, one or more layers or sheets of fabric 28, 30, 32, and/or 34 may be pliable, that is, easily bent or deformed. In one aspect, the one or more layers or sheets of fabric 28, 30, 32, and/or 34 comprises a knitted fabric comprising one of a polyethylene terephthalate (PET), polyester, and an aramid polymer.

According to aspects of the invention, the fluid 20 in internal cavity 21 and the elasticity of upper wall 14, lower wall 16, and sidewalls 18 provide a unique energy dissipating function that minimizes or reduces the loading transmitted on, for example, upper wall 14 to lower wall 16. This energy or impact-dissipating characteristic of liner 10 can provide an effective device for dissipating the transfer of energy and/or loading upon a surface, such as, the head of a wearer of a helmet having liner 10.

Though not shown in FIGS. 1 and 2, aspects of the invention may include interface elements as shown and described in pending U.S. application Ser. No. 17/303,734, filed on Jun. 7, 2021, and/or interface elements as shown and described in-pending U.S. application Ser. No. 17/020,888, filed on Sep. 15, 2020, the disclosures of which are included by reference herein in their entirety.

In one aspect, the construction of liner 10 having an upper wall 14, a lower wall 16, a fluid 20, and posts or pins 22 may be employed for the liner shown in FIGS. 25, 26, and 27 in pending application Ser. No. 17/303,734, for example, as a liner in a “bump cap,” as known in the art.

As shown in FIGS. 1 through 2, in one aspect, liner 10 may comprise a plurality of lobes, sections, or portions 36, 38, 40, and 42 extending from central lobe, section, or portion 44. According to one aspect, at least one of the portions 36, 38, 40, 42, and 44 have posts or pins 22; however, typically, each of the portions 36, 38, 40, 42 and 44 have posts or pins 22. For example, lobes or portions 36 and 40 may be side lobes, lobe 42 may be a rear lobe, and lobe 38 may be a front lobe of liner 10. According to aspects of the invention, lobes or sections 36, 38, 40, 42 and/or 44 may define recesses or cavities 46. In one aspect, lobes or sections 36, 38, 40, 42 and/or 44 may be internally isolated or separated by restrictions, for example, to regulate or vary fluid flow between sections, as disclosed in pending U.S. application Ser. No. 17/020,888 filed on Sep. 15, 2020, the disclosure of which is incorporated by reference herein in its entirety.

In one aspect, lobes or sections 36, 38, 40, and/or 42 may include flaps or “ears” 48, for example, extending from one or more of the lobes or sections 36, 38, 40, and/or 42. In one aspect, flaps 48 may be provided to facilitate the fabrication process, for example, to remove a molded portion of liner 10 or portions of liner 10 from a mold. In another aspect, flaps 48 may provide an innocuous location for introducing user readable indicia, for example, a liner model number, a logo, a date of liner fabrication, and/or related information.

Lobes or sections 36, 38, 40, 42, and 44 may be shaped and positioned wherein, when liner 10 is placed in helmet shell (not shown), recesses or cavities 46 may be substantially eliminated wherein adjacent surfaces of lobes 36, 38, 40, 42, and 44 may abut each other to form a substantially continuous barrier. Though, in one aspect, the contact between sections 36, 38, 40, 42, and 44 may be continuous, in other aspects, it is envisioned that some separation may be present between adjacent sections 36, 38, 40, 42, and 44 along lines of contact.

FIG. 3 is a cross sectional view of a portion of the helmet liner 10 shown in FIG. 2 as viewed along section lines 3-3 shown in FIG. 2. As shown in FIG. 3, flexible, fluid impermeable enclosure 12 of impact dissipating helmet liner 10 includes the upper wall 14, the opposing lower wall 16, the cavity 21 of enclosure 12 containing the fluid 20; and the plurality of cylindrical posts or pins 22 extending from the lower wall 16 to the upper wall 14. As also shown in FIG. 3, liner 10 may include one or more holes or cavities 24 between the upper wall 14 and the lower wall 16, the holes or cavities 24 having sidewalls 26 extending from the upper sheet or wall 14 to the lower sheet or wall 16.

As shown in FIG. 3, in one aspect, lower wall 16 and pins 22 may be integrally fabricated, for example, molded as an integral component, and upper wall 14 may be a separate component, fabricated separately, and then mounted or fixed to the upper or distal ends of pins 14. For example, in one aspect, upper wall 14 may be mounted to the distal ends of pins 22 (and, if present, the distal ends of sidewall 18 and sidewalls 26) by the processes disclosed in U.S. Pat. No. 10,531,699 of Kirshon, the disclosure of which is included herein in its entirety. Specifically, as shown and described with respect to FIGS. 9 through 18 of the '699 patent. For example, in one aspect, after formation of lower wall 16 and pins 22 (and, if present, sidewall 18 and sidewalls 26), upper wall 14 may be mated to the lower wall 16 and pins 22 (and, if present, sidewall 18 and sidewalls 26) by immersing the distal ends of pins 22 (and, if present, the distal ends of sidewall 18 and sidewalls 26) into a mold having an uncured or semi-cured fluid, and the uncured or semi-cured fluid is allowed to cure and engage the distal ends of pins 22 (and, if present, the distal ends of sidewall 18 and sidewalls 26). However, it is envisioned that in one aspect, upper wall 14, lower wall 16, and pins 22 (and, if present, the sidewall 18 and sidewalls 26) may be fabricated as a one-piece, integral component, for example, by molding.

FIG. 4 is a cross sectional view of a portion of the helmet liner 10 shown in FIG. 2 as viewed along section lines 4-4 shown in FIG. 2. FIG. 4 includes many of the structures identified in FIG. 3, including the upper wall 14, the opposing lower wall 16, and the plurality of cylindrical posts or pins 22 extending from the lower wall 16 to the upper wall 14. In the aspect of the invention shown in FIG. 4, the cross section and the relative location and positioning of fabric reinforcement 34 shown in FIG. 2 is shown. According to aspects of the invention, fabric reinforcements 28, 30, and 32 may have similar relative locations and positioning with respect to upper wall 14 of liner 10, respectively.

As shown in FIG. 4, in one aspect, fabric reinforcement 34 (and fabric reinforcements 28, 30, and 32) may be embedded in upper wall 14, that is, the outer wall of liner 10, for example, embedded in the material of upper wall 14, for example, an elastomeric material. However, it is envisioned that fabric reinforcement 34 (and fabric reinforcements 28, 30, and 32) may be positioned anywhere in upper wall 14, upon the surface of upper wall 14, and/or below the surface of upper wall 14 of liner 10. For example, as shown in FIG. 4, fabric reinforcement 34 (and fabric reinforcements 28, 30, and 32) may be positioned in a layer of material distinct from, for example, above, the upper wall 14 of liner 10.

FIG. 5 is a top perspective view of a portion 50 of a liner according an aspect of the invention. For example, portion 50 may be the bottom or lower portion of a liner fabricated from, for example, two portions. In one aspect, portion 50 may be referred to as the “A-mold” portion of a liner fabricated from two-portions: an “A-mold” portion and a “B-mold” portion—for example, as described in pending application Ser. No.16/595,135, the disclosure of which is included by reference herein in its entirety. The A-mold portion may comprise at least the lower wall 16 and pins 22 (and, if present, the sidewall 18 and sidewalls 26), as shown in FIGS. 1 through 4, and the B-mold portion (not shown in FIG. 5) may comprise at least the upper wall 16, as shown in FIGS. 1 through 4.

FIG. 6 is a bottom perspective view of the portion 50 of the liner of the aspect of the invention shown in FIG. 5. Portion 50 shown in FIGS. 5 and 6 may be used to fabricate a liner according to aspects of the invention, for example, similar to and having the features of liner 10 shown in FIGS. 1 through 4.

As shown in FIGS. 5 and 6, liner portion 50 includes a wall or sheet 52, a sidewall 54 extending from the sheet 52, and a plurality of cylindrical posts or pins 56 extending from the sheet 52. As shown, posts or pins 56 may be distributed about sheet 52, for example, uniformly distributed. In one aspect, each of the plurality of cylindrical posts or pins 56 may comprise a solid post or pin, for example, having little or no internal cavities, voids, holes, or hollows. In one aspect, the cylindrical posts or pins 56 may include one or more voids, for example, a hollow or a hole, for example, an axially directed cylindrical hollow or axially directed cylindrical through hole.

As also shown in FIGS. 5 and 6, in one aspect, the liner portion 50 may further include at least one hole or cavity 58 having sidewalls 60 extending from sheet 52. At least one hole or cavity 58 may be a through hole or a blind hole, for example, having one or both ends sealed or covered, for example, by a portion of sheet 52. According to one aspect, the sidewalls 60 defining the cavities 58 may distinguish from the solid, cavity-less posts or pins 56 disclosed herein. In one aspect, it is envisioned, that holes or cavities 56 and sidewalls 58 may be omitted.

As shown in FIGS. 5 and 6, in one aspect, liner portion 50 may comprise a plurality of lobes, sections, or portions 62, 64, 66, and 68 extending from central section or portion 70. According to one aspect, at least one of the portions 62, 64, 66, 68, and/or 70 have posts or pins 56; however, typically, each of the portions 62, 64, 66, 68, and/or 70 have posts or pins 56. According to aspects of the invention, lobes or sections 62, 64, 66, 68, and 70 may define recesses or cavities 72 between adjacent lobes. In one aspect, lobes or sections 62, 64, 66, and/or 68 may include flaps or “ears” 74, for example, extending from one or more of the lobes or sections 62, 64, 66, and/or 68. In one aspect, flaps 74 may be provided to facilitate the fabrication process, for example, to remove molded portion from a mold.

Lobes or sections 62, 64, 66, 68, and/or 70 may be shaped and positioned wherein, when liner portion 50 is mated to another liner portion (not shown) and placed in helmet shell (not shown), recesses or cavities 72 may be substantially eliminated wherein adjacent surfaces of lobes 62, 64, 66, 68, and/or 70 may abut each other to form a substantially continuous barrier.

As shown most clearly in FIG. 6, in one aspect, liner portion 50 may include one or more layers or sheets of fabric 76, 78, 80, and/or 82, as disclosed herein. For example, one or more woven, non-woven, knitted, or non-knitted fabrics or sheet materials that may provide at least some structural reinforcement to liner portion 50. As shown by sheet 82 in FIG. 6, in one aspect, one or more embedded fabrics 76, 78, 80, and/or 82 may be used for text or user readable indicia, for example, a logo, a trademark, a certification mark, and/or instructions for use, among other things, for the liner formed from liner portion 50.

According to aspects of the invention, liner portion 50 shown in FIGS. 5 and 6 may be used to fabricate a liner according to aspects of the invention, for example, for fabricating a liner similar or identical to liner 10 shown in FIGS. 1 through 4. For example, in one aspect, a wall or sheet, such as, upper wall 14, may be mounted to the distal ends of pins 56 and of the distal ends of sidewalls 54 of liner portion 50 by the processes disclosed in U.S. Pat. No. 10,531,699 of Kirshon, the disclosure of which is included herein in its entirety. Specifically, a liner may be formed by the process shown and described with respect to FIGS. 9 through 18 of the '699 patent. For example, in one aspect, after formation of liner portion 50 having sheet or lower wall 52, sidewalls 54, and pins 56 (and, if present, the sidewalls 60), an upper wall (such as upper wall 14 shown in FIGS. 1 through 4) may be mated to the sheet or lower wall 52, sidewalls 54, and pins 56 (and, if present, the sidewalls 60) by immersing the distal ends of pins 56 and distal ends of sidewalls 54 (and, if present, the distal ends of sidewalls 60) into a mold (for example, referred to as a “B mold”) having an uncured or semi-cured fluid. The uncured or semi-cured fluid is allowed to at least partially cure and engage the distal ends of pins 56 and distal ends of sidewalls 54 (and, if present, the distal ends of sidewalls 60) to form a fluid-impervious enclosure, such as, enclosure 12 shown in FIGS. 1 through 4. According to aspects of the invention, an appropriate fluid, for example, a polydimethylsiloxane fluid, may than be inserted into the enclosure, for example, by syringe injection, to provide the desired fluid-containing liner disclose herein.

FIG. 7 is a cross-sectional view of a helmet 80 having either impact-dissipating liner 10 shown in FIGS. 1 through 4 or a liner 110 formed from liner portion 50 shown in FIGS. 5 and 6, according to an aspect of the invention. Helmet 80 typically includes a helmet shell 82, for example, a shell made from a plastic, such as, a polycarbonate. As shown in FIG. 7, liner 10 or no may be inserted into a helmet shell 82 and retained in helmet shell 82. The insertion of liner 10 or 110 into helmet shell 82 may be practiced by conventional means, for example, manually by a user or by automated means. The liner 10 or 110 may be retained in helmet shell 82 by conventional mean, for example, with an adhesive, with mechanical fasteners, such as, hook-and-loop type fasteners, and/or with appropriate webbing and/or constraints. Helmet 80 having liner 10 or no may comprise any one of the headgear or helmets disclosed herein, for example, a motorcycle helmet, a football helmet, or a construction helmet, among others.

FIG. 8 is a cross-sectional view of a representative portion of a protective barrier 90 having the structure of either impact-dissipating liner 10 shown in FIGS. 1 through 4 or of liner 110 formed from liner portion 50 shown in FIGS. 5 and 6, according to an aspect of the invention. As disclosed herein, protective barrier 90 may comprise any shape conducive to the desired application, for example, a hexahedron (such as, a cube, a rectangular prism, or a cuboid), a prism (such as, a triangular, pentagonal, or hexagonal, or octagonal prism), or a cylinder, such as, a right cylinder (such as, a circular, elliptical, triangular, rectangular, pentagonal, hexagonal, or octagonal, cylinder), among others.

Protective barrier 90 may be used to protect a surface 95, for example, a surface likely to be exposed to undesirable damage due to contact and/or impact loading. As disclosed herein, such surfaces may include bodily surfaces (for example, where barrier 90 may comprise body armor or padding), structural surfaces, and/or ornamental surfaces, among others. Protective barrier 90 includes a liner 10 or a liner no, for example, having a flexible, fluid impermeable enclosure 93 having an upper wall 94, a lower wall 96, a side wall extending between the upper wall and the lower wall (not shown), and a fluid 98, as disclosed herein. As disclosed herein, liner 10 or a liner 110 of protective barrier 90 includes a plurality of cylindrical posts 97 extending from the upper wall 94 to the lower wall 96, each of the plurality of cylindrical posts 97 at least partially restraining deflection of one of the upper wall 94 and the lower wall 96.

Protective barrier 90 may include a panel or wall 92, for example, a rigid panel or wall 92, made from a plastic, such as, a polycarbonate. In other aspects, panel or wall 92 may be omitted and protective barrier 90 may provide the desired protection of surface 95.

As shown in FIG. 8, liner 10 or 110 may be positioned against surface 95, and, if present, panel or wall 92 may be positioned against liner 10 or 110, for example, opposite surface 95. The positioning of liner 10 or 110 onto surface 95 and the positioning of panel or wall 92 upon liner 10 or 110 may be practiced by conventional means, for example, with an adhesive or with mechanical fasteners, such as, hook-and-loop type fasteners. Protective barrier 90 having liner 10 or 110 may comprise any protective barrier disclosed herein, including a motor sports barrier or a sport stadium wall barrier or arena wall barrier, among others.

According to aspects of the invention, the width or the thickness of the liner 10 or 110 or of the enclosure 12 or 93 of the liner disclosed herein may range from about 0.125 inches to about 3 inches, but is typically between about 0.25 inches and about 0.5 inches. The thickness of the sheet or walls 14, 16, and 52 may range from about 0.025 inches to about 0.50 inches, but is typically between about 0.050 inches and about 0.20 inches. The outside dimension or diameter of pins or posts 22 and 56 may range from about 0.05 inches to about 0.5 inch, but is typically between about 0.10 inches and about 0.30 inches.

According to aspects of the invention, the liners and liner portions disclosed herein, for example, liners 10 and 110 and liner portions 50, may be fabricated from any elastomeric material, for example, a natural or synthetic rubber, a foam, a thermoplastic elastomer, a polyurethane elastomer, a silicone elastomer, a polyvinyl chloride (PVC) elastomer, an olefinic elastomer, a polyamide elastomer, or a gelatinous elastomer, among others.

In one aspect, the liners 10 and 110 and liner portions 50 disclosed herein may be made from a silicone, for example, a liquid silicone rubber (LSR), or its equivalent. In one aspect, the liners and liner portions disclosed herein may comprise a liquid silicone rubber, for example, a cured liquid silicone rubber, such as, a platinum-cured LSR. In one aspect, the liners or liner portions disclosed herein may comprise a LSR marketed under the trademark True Skin®; however, the enclosures of the liners disclosed herein may comprise any cured liquid silicone rubber (LSR). In one aspect, the cured liquid silicone rubber may be a “medical grade” LSR, as known in the art, for example, an LSR having an elasticity, a viscosity, a “feel,” and/or anti-microbial properties, among other things, that are desirable in aspects of the invention.

However, in one aspect, a liquid silicone rubber marketed under the trademark True Skin® provided by the company CHT may be preferred. In one aspect, the enclosures disclosed herein may be made from CHT's True Skin® 10 having a 10 Shore A hardness (or durometer) as disclosed in CHT “Technical Data Sheet” for True Skin® 10 [Rev-1, 8-16-17], which is included by reference herein. In one aspect, the enclosures disclosed herein may be made from CHT's True Skin® 20 having a 20 Shore A hardness (or durometer) as disclosed in CHT “Technical Data Sheet” for True Skin® 20 [Rev-1, 846-17], which is included by reference herein. In one aspect, the enclosures disclosed herein may be made from CHT's True Skin® 30 having a 30 Shore A hardness (or durometer) as disclosed in CHT “Technical Data Sheet” for True Skin® 30 [Rev-1, 8-16-17], which is included by reference herein.

As known in the art, any one of the enclosures and liners disclosed herein may be fabricated from a liquid silicon rubber produced when combining two or more components, for example, a CHT True Skin liquid silicone rubber “A” and a CHT True Skin liquid silicone rubber “B” to produce the desired liquid silicone rubber when cured.

It is also envisioned that aspects of the invention may be made from other liquid silicone rubbers, for example, a LSR marketed under the trademark SILBIONE® by Elkem Silicones of Lyon, France, or its equivalent. For example, in one aspect, one or more of the LSRs identified in Elkem's “Silbione® Liquid Silicone Rubber (LSR) Elastomers” line card dated June 2018, which is included by reference herein, may be used for an aspect of the invention.

In another aspect, the enclosures of the invention may be made from a LSR marketed by Dow Corning, or their equivalent.

In another aspect, enclosures of any one of the liners disclosed herein may be made from a LSR marketed under the trademark DRAGON SKIN™ by Smooth-On, Inc., or their equivalent. For example, one or more of the LSRs identified in Smooth-On's Technical Bulletin “Dragon Skin™ Series,” having reference number 041619-JR, which is included by reference herein, may be used for an aspect of the invention.

According to aspects of the invention, the fluid 20 and 98 (for example, a liquid) encased in the enclosures of the liners disclosed herein, for example, liner 10, may comprise a polydimethylsiloxane fluid, for example, a polydimethylsiloxane fluid marketed as a QM Diluent by CHT, or their equivalents; however, the fluid may comprise any polydimethylsiloxane fluid. However, in one aspect, the polydimethylsiloxane fluid marketed under the trademark QM Diluent may be preferred. In one aspect, the fluid encased in the enclosures of the liners disclosed herein may comprise QM Diluent 50 having a viscosity of about 50 centipoises (cps) as disclosed in CHT “Technical Data Sheet” for QM Diluent 50 [Rev-3, Aug. 7, 2017], which is included by reference herein. In one aspect, the fluid encased in the enclosures of the liners disclosed herein may comprise QM Diluent 100 having a viscosity of about 100 cps as disclosed in CHT “Technical Data Sheet” for QM Diluent 100 [Rev-3, Aug. 7, 2017], which is included by reference herein. In one aspect, the fluid encased in the enclosures of the liners disclosed herein may comprise QM Diluent 1000 having a viscosity of about 1000 cps as disclosed in CHT “Technical Data Sheet” for QM Diluent 1000 [Rev-3, 8-7-17], which is included by reference herein. In one aspect, the fluid encased in the enclosures of the liners disclosed herein may comprise QM Diluent 5000 having a viscosity of about 5000 cps, for which a “Technical Data Sheet” has not been identified. It is envisioned that fluids of higher viscosity, for example, QM Diluents having a viscosity greater than 5000 cps may be used in aspects of the invention.

It is envisioned that fluids 20 and 98 having other viscosities, for example, QM Diluents provided by CHT, may also be used, for example, by appropriately combining at least two fluids of known viscosity, as known in the art. In one aspect, one or more fluids may be used to provide a viscosity of the fluid that may be as low as possible, for example, less than 50 cps or less than 25 cps, or even approaching or obtaining zero (0.0) cps. Accordingly, in one aspect, polydimethylsiloxane fluids of different viscosities, such as, a CHT QM Diluents, can be mixed or otherwise combined to provide a fluid having a viscosity of less than 50 cps or at most or at least 50 cps that can be used as a fluid in an aspect of the invention. Similarly, in one aspect, polydimethylsiloxane fluids of different viscosities, such as, a CHT QM Diluents, can be mixed or otherwise combined to provide a fluid having a viscosity of at least 100 cps that can be used as a fluid in an aspect of the invention. In one aspect, polydimethylsiloxane fluids of different viscosities, such as, a CHT QM Diluents, can be mixed or otherwise combined to provide a fluid having a viscosity of at least 500 cps that can be used as a fluid in an aspect of the invention. In one aspect, polydimethylsiloxane fluids of different viscosities, such as, a CHT QM Diluents, can be mixed or otherwise combined to provide a fluid having a viscosity of at least 1000 cps, or at least 2000 cps, or at least 3000 cps, or at least 4000 cps, or at least 5000 cps, or at least 6000 cps, or at least 8000 cps that can be used as a fluid in an aspect of the invention.

Aspects of the present invention provide versatile impact-dissipating liners for bodily and structural protection, among other uses. For example, when applied to head protection, aspects of the invention can provide head protection at both low--energy and high-energy impacts, from any direction, and at any one point in time. Moreover, unlike prior art head protection, aspects of the present invention have been tested and confirmed to provide repeatable impact protection, for example, protection from multiple impacts. In addition to the energy absorbing function of aspects of the invention, the lower-profile nature of aspects of the invention compared to the prior art can provide the benefit of reducing the transmission of rotational or torsional loading on the head, neck, and/or spine by providing a lower “lever arm” to any loading. For example, where the prior art is characterized by head protection having thicker liners, for instance, 2 to 3 inches thick, aspects of the present invention can be adapted to provide a liner thickness of only about ½ inch in thickness. As known in the art, this reduction in thickness, and thus reduction of impact torsional lever arm, can dramatically reduce the torsional loading upon the head, neck, and/or spine of the user.

It will be apparent from the foregoing that the invention, in its many aspects, provides impact-dissipating liners, method of fabricating impact-dissipating liners, helmets and headgear having impact-dissipating liners, arrangements, liners, and methods for protecting heads and other bodily structures, or other general non-bodily structures for which protection is desired. Again, though aspects of the invention were shown and described with respect to a headgear and helmets, it is envisioned that aspects of the invention may be used for any barrier, structure, or any impact-dissipating liner disclosed herein. In one aspect, a barrier for a motor sport may comprise one or more of the impact-dissipating liners disclosed herein, for example, a barrier or wall of a race track (for example, a motor vehicle race track) or a race course (for example, a motocross course), and the like.

Aspects of the invention may be applied to a broad range of helmet and/or headgear, including, but limited to, a baseball catcher's helmet, a baseball batter's helmet, a softball catcher's helmet, a softball batter's helmet, a hockey helmet, a hockey goalie mask, a motorcycle helmet, a motor cross helmet, a skiing helmet, a snowboarding helmet, a skateboarding helmet, a lacrosse helmet, a bicycle helmet, a jockey helmet, an official's helmet, a medical protection helmet, a rock or ice climbing helmet, a mountain climbing helmet, a football helmet, a construction helmet, and a military helmet.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises,” “comprising,” “including,” and/or “having” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

The description of the present disclosure has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the disclosure in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the disclosure. The embodiment was chosen and described in order to best explain the principles of the disclosure and the practical applications, and to enable others of ordinary skill in the art to understand the disclosure for various embodiments with various modifications as are suited to the particular use contemplated.

This written description uses examples to disclose the invention, including the best mode envisioned, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims. 

1. An impact dissipating helmet liner comprising: a flexible, fluid impermeable enclosure having an upper wall, an opposing lower wall, and a sidewall extending between the upper wall and the lower wall; a fluid contained in the enclosure; and a plurality of cylindrical posts extending from the lower wall to the upper wall, each of the plurality of cylindrical posts at least partially restraining deflection of one of the upper wall and the lower wall.
 2. The impact dissipating helmet liner as recited in claim 1, wherein the liner further comprises at least one cavity between the upper wall and the lower wall, the at least one cavity having the sidewall extending from the upper wall to the lower wall.
 3. The impact dissipating helmet liner as recited in claim 1, wherein each of the plurality of cylindrical posts comprises solid cylindrical posts.
 4. The impact dissipating helmet liner as recited in claim 3, wherein the solid cylindrical posts are devoid of any internal voids or cavities.
 5. The impact dissipating helmet liner as recited in claim 1, wherein the helmet liner further comprises at least one fabric sheet.
 6. The impact dissipating helmet liner as recited in claim 5, wherein the at least one fabric sheet comprises one of a woven fabric, an unwoven fabric, and a knitted fabric.
 7. The impact dissipating helmet liner as recited in claim 5, wherein the at least one fabric sheet comprises a knitted fabric comprising one of a polyethylene terephthalate (PET), a polyester, and an aramid polymer.
 8. The impact dissipating helmet liner as recited in claim 1, wherein the flexible, fluid impermeable enclosure comprises a central portion and a plurality of lobes extending from the central portion, and wherein the central portion and the plurality of lobes are adapted to conform to the shape of an internal surface of a helmet.
 9. The impact dissipating helmet liner as recited in claim 8, wherein the plurality of lobes defines radially extending cavities between adjacent lobes.
 10. The impact dissipating helmet liner as recited in claim 1, herein the flexible, fluid impermeable enclosure comprises a silicone rubber.
 11. The impact dissipating helmet liner as recited in claim 1, wherein the fluid comprises a liquid.
 12. The impact dissipating helmet liner as recited in claim ii, wherein the liquid comprises one of liquid silicone rubber, a polydimethylsiloxane, and a polyol.
 13. The impact dissipating helmet liner as recited in claim 1, wherein the helmet liner comprises a liner for at least one of a baseball catcher's helmet, a baseball batter's helmet, a soft ball catcher's helmet, a softball batter's helmet, a hockey helmet, a hockey goalie mask, a motorcycle helmet, a motor cross helmet, a skiing helmet, a snowboarding helmet, a skateboarding helmet, a lacrosse helmet, a bicycle helmet, a jockey helmet, an official's helmet, a medical protection helmet, a rock or ice climbing helmet, a mountain climbing helmet, a football helmet, a construction helmet, and a military helmet.
 14. A helmet having the impact dissipating helmet liner as recited in claim
 1. 15. The helmet as recited in claim 14, wherein the helmet comprises a helmet shell containing the impact dissipating helmet liner.
 16. A protective barrier comprising: a flexible, fluid impermeable enclosure having an upper wall, an opposing lower wall, and a sidewall extending between the upper wall and the lower wall; a fluid contained in the enclosure; and a plurality of cylindrical posts extending from the upper wall to the lower wall, each of the plurality of cylindrical posts at least partially restraining deflection of one of the upper wall and the lower wall.
 17. The protective barrier as recited in claim 16, wherein the protective barrier comprises an impact-dissipating protective barrier.
 18. The protective barrier as recited in claim 16, wherein the protective barrier comprises at least one of body armor, body padding, a wall padding, and a surface padding.
 19. The protective barrier as recited in claim 16, wherein the protective barrier comprises a protective barrier for motor sports.
 20. The impact dissipating liner as recited in claim 16, wherein the flexible, fluid impermeable enclosure comprises a thickness ranging from 0.125 inches to 3 inches. 